Cylinder block



y 4 I. M. II'AYLOIR 2,444,963

. CYLINI JER BLOCK Filed June 2, 1944 r 2 Sheets-Sheet 1 INVENTUR LLOYD M. TAYLOR -@4 I I A ORNE'YI' July 13, 1948.

L. M. TAYLOR cumnsn BLOCK 2 Sheets-Sheet 2 Filed June 2, 1944 mvsmox LLOYD M.TAYLOR.

AT TORNEY:

Patented July 13, 1948 Lloyd M.

Taylor, San Leandro, CaliL, assignoi to a 'Taylor Engines, Inc., San Francisco, Calif., a corporation of Nevada Application June 2, 1944, Serial No. 538,392 I 9 Claims. 1

The invention, in general, relates to a fabricated or built-up structure formed of a plurality of related, suitably shaped parts which are united permanently together in an integral unit. More particularly, the invention relates tov a fabricated cylinder block which is suitable for adaptation to compressors, internal combustion engines or other power devices.

While the present invention, as above indicated, is entirely suitable for application to compressors and like units, the preferred embodiment of the invention herein illustrated hasbeen developed for adaptation to internal combustion engines and shall be described, forpurposesof explanation only, in that environment.

Because of their peculiar shapes or design, as well as the various structural problems involved in their design and manufacture, as applied to internal combustion engines, cylinders and cylinder heads therefor heretofore'h'ave been produced only either by forging or casting to shape with subsequent machining to predetermined dimensions. The manufacturing requirements of forging or casting inherently limit the end product and this is particularly the case as to. castings where high strength material cannot be employed with success. Moreover, the shapes of the parts of the resultant cylinder block are such that they cannot be formed without,the use of excess material resulting in an increased weight as well as loss of heat dissipation at many critical points. As a consequence, cylinder blocks formed from castings or forgings have been found to be not only too heavy per developed horsepower for practical purposes and desired emciency but practically all engines employing such type of cylinder block are incapable of transmitting or dissipating heat as rapidly as desired.

The present invention is directed to a method of fabricating a cylinder block containing one or more cylinders formed from standard sheet steel because of internal stresses setup. In the development of the present invention, the problems I aforementioned as well as others have been overcome by'so forming the parts of the block that they conform to the lines of greatest stress and so shaping and evolving each element that it will transmit its load to adjoiningparts of the strucand steel tubing to afford in an internal combustion engine employing such a block a more emcient engine which can be manufactured in a more expeditious and economical manner. Previous work along-these same lines, in general, and employing tubing and sheet steel, has been unsuccessful principally because'of the failure to solve the structural problems involved as well as failure to obviate excess material and weight in the uniting of the somewhat intricately shaped parts. Moreover, prior machines containing sheet metal and tubing cylinder blocks were found deficient in their performance due to undue warping" of parts either during assembly or in service ture with! the result that the metal parts do not flex, fatigue or accumulate stresses at points of possible weakness. Moreover, the preferred embodiment of the present invention has been so devised from the employment of and shaping of rolled and extended sheet steel parts as to cause the grain of the metal to follow the lines of highest stress in all instances under performance which, in turn, has enabled the use of relatively thin sections throughout the structure. In addition, the cylinder block of the invention is so manufactured that oven brazing to unite preassembled parts permanently together is peculiarly advantageously adaptable with the result that all joints united are connected at the same time and at the same temperature thus eliminating the possibility of accrued internal stresses or warping of the assembly due to uneven heat as would occur in gas or arc welding.

A primary object of the present invention is to provide an improved fabricated cylinder block formed of sheet metal and steel tubing of uniform thin section which, as applied to an internal combustion engine, developes no hot spots, affords rapid and effective dissipation of heat from combustion to coolant, and which includes parts not subject to flexing or fatigue.

Another important object of the invention is to provide a built-up cylinder block of the indicated nature, for application to an internal combustion engine, which is additionally character ized by its ability to withstand pulsating stresses of :ombustion to an optimum extent.

A still further object of my invention is to provide a fabricated cylinder block for use in an internal combustion engine and which has a minimum of weight per developed horse-power of the engine.

Another object of the present invention is to provide an improved fabricated cylinder block of greater rigidity, higher stress-resisting characteristics, and capable of withstanding extremes in temperature or other abuses.

A still further object of my invention is to provide an improved method of fabricating a cylinder block which is of greater economy, greater efliciency, greater simplicity and which lends itself admirably to mass production.

Other' objects of the invention, together with, some of the advantageous features thereof, will appear from the following description of my preferred method of manufacturing a preferred embodiment of the invention whichis illustrated in the accompanying drawings. It is to be understood that I am not. to be limited to the precise manufacturing steps set forth, nor to the precise embodiment of the invention shown, as my invention, as defined in the appended claims, can be practiced in a variety of ways and can be embodied in a plurality and variety of forms.

Referring to the drawings:

Figure 1 is a cut-away, fragmentary perspective view of a preferred embodiment of the invention, as adapted to an internal combustion engine.

Figure 2 is an enlarged, fragmentary longltudinal sectional view of the preferred embodiment of the invention shown in Figure 1.

Figure 3 is an enlarged, fragmentary transverse sectional composite view, similar to the 'parts shown in Figure 2, but illustrating an alpermanently united to each head and reinforcing the same against deformation from the pres sure of combustion; said elbows supporting a valve seat as well as a valve guide, a water Jacket surrounding said cylinders, heads and elbows;

said water jacket reinforcing said elbows in the direction in which they tend to collapse, together with a cylinder hold-down structure permanently united to each cylinder for collecting the loads or drawings, my improved fabricated. cylinder block includes as principal perm, a plurality of separately mounted cylinders, individual heads for the cylinders, a pair of conduits in the form of e1- bows united to each head and including integral valve-guide supports, a water jacket, a reinforcing structure 'at the top of the block tying the elbows together to lend rigidity thereto as well as serving as a housing and support for the cam maft assembly, not shown, and a cylinder holddown unit'which serves to collect stresses from the walls of the cylinders and to transmit the stresses directly to a case or other support.

In accordance with my invention, I provide in my improved fabricated cylinder block a plurality of cylinders II which all are of the same dimensions and preferably formed from drawn steel tubing of high tensile strength. but of uniform thin section. Naturally, the thickness of the tubing section of cylinders ll may be increased or decreased depending upon the size of the compressor or internal combustion engine in which the block is to be employed. As illustrated, individual one-piece cylinder heads l2 are provided for each cylinder and each head is pref- 4 erably fabricated from sheet metal stamping so formed as to provide therein suitable valve ports I 3 and I4, bounded by an approximately 45 surface for receiving the valve seats, as well as to afford spark-plug openings l9 therein. If desired, the upper rim of the cylinders as well as the depending flange of each of the heads l2 can be threaded for temporarily connecting these parts together prior to the final brazing step. Preferably, a copper ring, designated by the reference numeral I5. is applied at the Joints between the cylinders and cylinder heads which melts when the assembled block is subjected to- 'theaction of a hydrogen-copper brazing furnace or oven thus permanently uniting these parts together.

To reinforce the cylinder heads [2 against deformation from the pressure of combustion, I provide a pair of specially formed conduits i1 and I9, in the shape of elbows, which serve to conduct the combustible charge and exhaust gases, respectively, from and to the intake and exhaust manifolds of the engine, not shown. Each ofthe elbows is preferably formed of two complementary half-sections stamped from thin section, light-weight sheet metal and so shaped as to provide, when the half-sections are permanently united together in proper alignment, integral valve-guide supports l9 so arranged thereon and disposed as to be in alignment with the valve ports l3 and ljofthe cylinder head with which the' elbows are associated. As illustrated particularly in Figures 2 and 3 of the drawings,

which preferablyare made from suitable hard facing, acid and heat-resisting alloy, such as stellite or the like. The elbow stampings also are so formed as to provide a crimp therein adjacent their inner ends, such crimping affording a head 22 which seats on top of the cylinder head l2 and which, in conjunction with the flaring inner extremities of the elbows, provides a lockjoint between the elbows and the heads. In addition to these lock-joints, which results from press-fitting the elbows in position, the meeting surfaces of the elbows and cylinder heads are coated with suitable copper paste so that the parts are permanently united by brazing when the assembled block is placed in a brazing oven. Suitable reinforcing webs 23 are provided on the elbows I1 and 48 by suitably shaping the elbow stampings, such webs extending in both directions from the valve-guide supports I9 to adjacent the opposite extremities of the elbows. Moreover, I so form the elbow stampings that a head 24 is formed on each valve-guide support I 9 which defines an inner recess or groove for assisting in locking a valve-guide liner 26 in position within each support l9 for in turn receiving the valve guides 21; the liners 28 each being provided with a bead 28 thereon fitting the recess formed in the valve-guide supports i9. For the purpose of assembly and to form a tight joint for assuring welding, each liner 28 is so formed with an out-turned flange 29 on its upper end that the parts are held rigidly together, the flange 29 also serving as a seat for a flange 9| formed on the valve-guide 21 which is pressfitted but not welded in position.

In the present embodiment of my improved fabricated cylinder block, I provide a main water outer surface of the bottom of the reinforcing box-like, structure 34 provided at the top of the block. As clearly shown in Figures 1 and 3 of the drawings, the upper box section of water jacket 32 is mounted in an inverted position and the stamping so formed as to provide suitably spaced openings 35 for establishing communication between the elbows l1 and i8 and main intake and shown at the right of Figure 3 and is formed in a boss 53 provided in the cylinder head stamping, with a flanged spark-plug bushing 54 staked therein. In the latter arrangement, it is necessary to form an oil-set in the water jacket 32, as

indicated by the double dotted line showing of Figure 3. The bushing 54 is rigidly supported by welding theflange to the outer surface of the water jacket.

cylinder block. as adapted for use in an internal combustion engine, includes a reinforcing boxexhaust manifolds of the engine, not shown.

While any suitable union for connecting the elbows to these main manifolds may be employed, I preferably provide flanged, threaded unions 36 for this purpose. each of which is screwed into a threaded ring 31Lspun into each elbow and fitting a recess deflned-I; -.by forming a relatively large bead 38 on the elbow stampings adjacent their outer extremities. shown particularly in Figure 3 of the drawings, the flange of each union 36 abuts the outersurface of the upper box section of Water jacket 32 bounding theopenings 35 therein. Thus, the elbows are firmly held against thewater jacket and a seal is provided therebetween. Although not shown in the drawings, the bottom of the lower box section of water jacket 32 is formed with a plurality of suitably spaced large openings for passing the cylinders and such large openings are preferably forme d by striking up the bottom of such lower box section thus affording upstanding flanges to which the cylinder skirts are directly and permanently united by brazing in the final brazing operations.

A modified form of the improved fabricated cylinder block of the present invention can include auxiliary water jackets 42 surrounding the valve guides 21 within the elbows i1 and I8, as

' illustrated in Figures 2 and 3 of the drawings.

These auxiliary water jackets 42 are especially advantageous when the cylinder block of my invention is employed in relatively large internal combustion engines. These auxiliary water jackets are permanently united to the inner Walls of the elbows l1 and I8 by means of outturned flanges 43 and 44 and by welding the flanges to the walls of the elbows. Preferably, for purposes of rigidity, I provide a threaded boss 46 in the bottom of each auxiliary water jacket 42 into which the threaded inner end of a modifled guide liner 26 may be screwed. To establish communication between the main water like structure 34 at the top of the block which not only lends rigidity to the upper portion of the block by tying all of the elbows l1 and I8 firmly together but also serves to support a camshaft assembly, not shown, as well as to house other non-moving parts. As shown, the reinforcing box-like structure 34 comprises a unitary three sided box-like member which is preferably stamped from sheet steel of thin section and which is so formed as to provide a plurality of suitably spaced openings therein for passing the valve guide liners 26 and valve guides 21. Moreover, the reinfprcing structure 34 includes a top which is permanently united to the sides and ends of the structure by means of brazingand which likewise is fabricated from sheet metal stamplngs formed so as to provide a plurality of suitably spaced large openings therein as well as a continuous perimeter groove 58 for receiving and holding a cam-shaft cover gasket, not shown, in

- place. To lend further rigidity to the block, it is jacket and each of the auxiliary water jackets for circulation of the coolant, each of the elbows I1 and I8 is provided with a plurality of ports or openings 4'l therein. In this modified embodiment of the invention, the spark-plug openings l6 may be arranged in either one or the to be observed that the flange, of each'va lve guide liner 26 seats on thebottomofa valve tappet guide 6| which is housed in the box-like structure 34, each of the valve tappet guides having an opening in the bottom thereof for passing the liners and the valve guides which also pass through aligned openings provided in the bottoms of the water jacket and the box-like structure, above mentioned. In Figure 1 of the drawings I have illustrated a lap joint between the'top of the box-like structure 34 and each of the valve tappet guides 6|, formed by striking out the openings in said top to provide flanges 62 at each opening and thus affording appreciable welding surfaces for uniting the tappet guides thereto, the upper rims 63 of which are flared outwardly to affordthe lap joint. Another method of uniting these last mentioned parts together is shown in Figure 3 of the drawings wherein there is depicted butt joints between the upper rims of the straight-walled tappet guides 6| andthe inner surface of the top of the box-like structure 34. Moreover, I provide flanged tappet guide liners 64 which snugly fit into the tappet guides and which are welded into position with the flanges 65 of the liners 84 seated on the upper surface of the top of the structure 34 and permanently united thereto. It also is to be noted that the meeting surfaces of the walls of adjacent valve tapp'et guides 6| are coated with copper paste during the assembly of the block so that adjacent guides 6| will be permanently united together in the flnal brazing operation. In order to take care of the load of the cam shaft bearings, not shown, a plurality of reinforcing webs 58 are provided within structure 34 under each of the cam shaft bearings. To furnish a level mounting for the latter bearings, a requisite number of pads 61 are mounted on and permanently united to the upper surface of the top of the structure 34 for receiving the cam shaft bearin s. the upper surfaces of all pads 81 being so machined that they all lie in the same horizontal plane. As shown in Figure 2 a suitable drain pipe 68 is fitted-to the bottom of the structure 34 for returning excess oil therefrom back to the crankcase, not shown.

In accordance with my present invention, and as shown in fragmentary, cut-away perspective in Figure 1 of the drawings, a specially constructed cylinder hold-down structure, or unit .H is provided in the improved cylinder block as adapted for use in an internal combustion engine. for collecting the stresses from the walls of the cylinders and distributing the same so as to be transmitted directly to the crankcase or other support for the block. The cylinder hold-down unit II comprises a generally box-like member including an integral or unitary cover including a top 12, a pair of ends l8,- and a pair'of sides .14, the integral cover being formed from sheet metal stamping of thin, uniform section and being provided with not only a plurality of relatively large, spaced openings for passing the skirts of the cylinders ii but also with a plurality of pairs of alignedsmaller openings 18 for passing throughbolts, not shown, employed for detachably'connecting the block to a crankcase pr other support, not shown. The cylinder hold-down unit-II also includes a specially formed bottom 11 which is permanently united to the sides and ends of the cover of the unit by means of brazing and which is so-formed from sheet metal stamping of the same thin section as the balance of the unit as to provide a plurality of aligned pairs of generally pyramid-shaped members 18 each of which has an opening formed in the apex thereof in registry with the smaller openings 18 of the top of the cover of the unit II. The bottom 11 of the hold-down unit also is provided with a pinrality of relatively large, spaced openings for passing the skirts of the cylinders ll, these relatively large openings being aligned, of course, with the large openings in the top 12. It is to be especially noted that in stamping out the top and bottom of the hold-down unit and in forming the large openings therein for passing the cylinders. I provide a bounding flange 81 around each opening in the top 12 and a bounding flange 82 around each opening in the bottom II, by striking out the metal, and thus ailord appreciable welding surfaces to which the cylinders are permanently united in the brazing step. It is to be further noted that the pyramid-shapedmembers II, which are so aligned in pairs as to surround the cylinders circumferentially, extend upwardly from the flanges 82 to the top of the unit and upwardly from the ends and sides of the unit to the top thereof. To complete the hold-down unit II, I provide elongated bolt-guide elements 83 within each of the pyramid-shaped members 18 with the bore of each element 83, of course, in registry with the opening 79 in the apex of each pyramid-shaped member; the elements 81 all being permanently united in position by brazing and seated on the top of the crank-case or other support for the block, not shown. These elements 8! are in effect hollow rivets serving not only as guides for the through bolts, above mentioned, but also as a means for enhancing the rigidity of the hold-down unit. Suitable washers 84 are provided for each of the throughbolts that pass through the guides 83, these washers 84 being welded inposition on the top of the cover of the hold-down unit.

As shown in Figure 1' of the drawings, a suitable cover II is provided for the block, so stamped from sheet metal of uniform thin section as to provide curved inturned flanges ll on its sides to enable the cover to be sprung into the perimeter groove Bl formed in the top of the box-like structure ll. Suitable bolts 87 are provided for firmly holding the cover in position.

with reference to Figure 2 of the drawings, and particularly to the dotted triangles designated by the reference characters A, B, C and P, D, E. It willbe observed that thecylinderheads I! have substantially flat tops, which under normal working pressures with the block adapted to an internal combustion engine, would tend to dome ou These flat tops of the heads I! constitute the bases of the above mentioned triangles, with the elbows generally constituting the sides of such triangles. Consequently, it can be seen that the combination of the elbows and cylinder heads as formed and associated for each of the separate cylinders of the block constitute, ineffect, a triangular bridge truss extending the length of the block thus affording increased rigidity and strength thereto. This rigidity and strength of these bridge trusses is augmented by virtue of the fact that at the apices of the triangles formed bythe elbows and heads, the elbows are all tied together by the top of the water jacket as well as the bottom of the boxlike structure 34. Moreo'ver,it is to be observed that the center of pressure of the combustion chambers of the cylinders is located betweenthe elbows l1 and i8, as indicated by the reference letters 01?, and this pressure is withstood by this simulated bridge truss formation of these elbows and tops of the heads I2; the force components of these parts being designated by the dotted triangles indicated in Figure 2. Similarly, it is to be noted that the hold-down unit II is of bridge truss formation with the top 12 of the unit com-. bining with the pyramid-shaped members 18 to constitute generally triangular shaped trusses.

throughout the length and width of the block, thus affording increased strength and rigidity thereto adjacent the bottom of the block. Likewise, the general formation of the box-like structure 34, with its webs 86 and the arrangement of the various valve tappet guides therewithin,

presents a bridge truss throughout the length and width of the block and affording increased strength and rigidity at the top thereof.

, It is to be understood that all of the various parts of my improved cylinder block are assembled on suitable jigs, with the adjacent parts preliminarily spot-welded in position pending the final brazing operation. Moreover, that the meeting surfaces of all adjacent parts are either coated with a suitable brazing paste, such as copper paste or a ring of copper is applied at the various joints which melts in the final brazing steps to unite the parts together permanently. Furthermore, the joints of all parts fitted together are placed under tension and compression and remain in such state throughout the brazing operation which conveniently is carried out in a suitable hydrogen-copper brazing oven. It is important that all connected, adjacent parts are firmly held together under tension and compression to insure welding and permanent bonds.

It is to be further understood that the appended claims are to be accorded a range of equivalents commensurate in scope with the advance made over the prior art.

Iclaim:

1. A fabricated cylinder block, said cylinder block consisting of a. plurality of separately mounted cylinders, a head on each cylinder having valve ports, in the top thereof, intake and water jacket being supported by the tops of said valve guide supports and connecting all of said supports rigidly together, a box-like structure united to the top of said water jacket, and a cylinder hold-down unit for collecting stresses from the walls of said cylinders and distributing the stresses to a crankcase or other support for theblock; said hold-down unit having a plurality of large openings therein for passing said cylin-' tiers and being directly united to said cylinders adjacent said openings. 1

2. A fabricated cylinder block comprising a plurality of separately mounted cylinders, a head on each cylinder; each of said heads including a substantially flat top having valve ports therein, a plurality of conduits directly united to the top of each of said heads, and a. valve guide support integral with each of said conduits in alignment with a valve port of said head; said cylinders being fabricated of uniform thin section tubing and said heads and said conduits including said valve guide support being fabricated from sheet metal stampings of uniform thin section.

3. A fabricated cylinder block as defined in claim 2 including a water jacket surrounding said cylinders, said heads and said conduits in spaced relationship thereto; said water jacket being united to and supported on the tops of said valve guide supports and connecting all of said supports rigidly together.

4. A fabricated cylinder block comprising ato an internal combustion engine consisting of a plurality of separately mounted cylinders; said block comprising a series of three bridge-truss units arranged in horizontal parallel relationship; said bridge-truss units consisting of a boxlike structure at the top of the block for housing a cam shaft assembly and including therein a plurality of reinforcing webs, a triangular bridge truss assembly consisting of a plurality of individual cylinder heads united to the tops of the engine cylindersand each-having a pair of valve ports therein, and a pair of conduits on each head and communicating with said valve ports and held together by said box-like structure, and a third bridge truss unit adjacent the bottom of the block: said third bridgetruss unit consistto said box-like structure at 10 ing of a box structure including a top, apair of ends. a pair of sides, a bottom, and a plurality of pyramid-shaped reinforcin bodies within said I boxstructure directly united to the external surface of each cylinder.

6. A fabricated cylinder block as defined in claim 5 including a valve guide support on each of said conduits, and a water jacket supported by the tops of said valve guide supports and united said water jacket surrounding the engine cylinders, said heads and said conduits in spaced relationship thereto and including a bottom having a plurality of openings therein for passing the engine cylinders, said bottom including flanges bounding said openings for uniting said water jacket directly to each of said engine cylinders.

7. In a fabricated cylinder block, a triangular bridge truss assembly consisting of a plurality of individual cylinder heads each having a, pair of valve ports therein in juxta-position, a pair of conduits united directly to said heads and communicating with said valve ports; each of said conduits being fabricated of complementary half comprising a cylinder hold-down unit including integral top,

ends and sides and a bottom directly united to said ends and sides, and a plurality of pyramid-shaped reinforcing bodies within said hold -down unit and arranged in aligned pairs; each of said pyramid-shaped reinforcing bodies being united directly to the cylinders Of the block and serving to collect stresses from the walls of the cylinders and to transmit the same to a crankcase or other support for the block.

valve ports therein,

9. A fabricated cylinder block for engines and compressors, said block comprising a cylinder sleeve,ja head on said sleeve; said head having communicating with said ports and united permanently tosaid head, valve guide supports integral with said conduits and in alignment with said ports, a water jacket surrounding said sleeve, said head and said conduits and united directly to the tops of said supports, and a hold-down unit for said sleeve united directly thereto for collecting stresses from the wall thereof and distributing the stresses to a crankcase or other support for the block.

LLOYD M. TAYLOR.

REFERENCES crrnn The following references are of record in the file of this patent:

UNITED STATES PATENTS the top of the block;

intake and exhaust conduitsv 

